Part 7 - Final Elements of conversion

The project has finally come to this - the last Part. We'll show a few last items to polish off the creation of the SubaruVanagon, then we'll go for a test drive! Enjoy!

Overview and Approximate Time Needed:

Steps

Process Description

~ Time (hours)

1

Belt guards

1

2

Alternator Light Fix

1

3

Testing

1

* Approximate Total Time =

3

*When you factor in rest and prep time, a mechanically inclined person should reserve a couple of hours to complete this process. For someone new to working on cars, this may take a little longer.

Tools you may need:

1. Metric socket and wrench sets, 10mm, 12mm, 13mm, 14mm, 17mm

2. Angle grinder or hacksaw and metal file

3. Soldering iron and wire connectors

Step 1: Belt Guards

A few safety elements and finishing touches to wrap up the install of our Subaru motor. Belt guards look pretty cool in my opinion - they finish things off a little.

Take the metal radiator hose protector (blue square) from the Waterboxer motor and clean up to install as a belt guard on the Subaru EJ22.

Its a pretty close fit between the alternator belt and the radiator hose so this guard should protect the hose if the belt fails and flails around.

Using the original belt guard from the Subaru, I cut the guard in half and rounded the edges with an angle grinder.

Then installed the new belt guard in the factory location. Since we only have one belt now it makes for a simple installation.

The subaru charcoal canister connections can be plugged or looped into each other. They are only activated if using a speed sensor. 90-95 model year 2.2L Subaru's usually don't need a speed sensor to operate normally.

Step 2: Alternator Light Fix

The alternator charge indicator light is super helpful. I had one conversion that I didn't take the time to get this done and woke up to a dead battery... in the middle of nowhere, not good! The belt had loosened and the alternator hadn't been charging the battery. I had unplugged the blue wire from the relay under the drivers seat so the blaring red ALT light would go away and I could forget about that part of the conversion - learn from me and don't do this! Follow along as we put pictures to a great diagram provided by www.subaruvanagon.com

This incredibly helpful diagram was provided by vwsyncroguy from www.subaruvanagon.com. This outlines the basic idea behind getting an alternator charge light to work in a Westy.

Here is the relay under the drivers seat. The wire we're concerned with here is the blue, which makes its way all the way from the alternator - Remember that so long ago???

I picked up a 5 pin relay at the auto parts store for under $10.

Here is the relay oriented to the original diagram. Pin 86 splices to the alternator blue wire, Pin 30 and 85 to Ignition On, Pin 87 is open, and Pin 87a will connect to the blue wire feeding the relay under the drivers seat.

A blurry night shot behind the fuse panel showing the wires that come from the underseat relay (black cable jacket in upper center of photo). We'll cut the wire and tie our "alternator light fix" relay into this blue wire on pin 87a to the cut side going to the underseat relay. The other cut end will provide our ground the the "fix" relay (it goes to the alternator).

Here is where I chose to place the "fix" relay, near the fuse panel so I could find a switched source for 12v and could also tie into the wire the feeds the underseat relay as well as the splice point for the blue wire from the alternator. I spliced a couple of extensions so I could place the relay near the other relays above the fuse panel.

Step 3: Test - The Subaru EJ22 purrs like a kitten... or roars like a tiger when fed

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The Final Test!

Now we'll see the performance gain from going from a Waterboxer to a Subaru. Take a look at the video below for a real world 0-60 test. These tests were performed near Durango, Colorado at an elevation of 7000ft above sea level. Lets have some fun!

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Summary

We hope you enjoy your new animal. We would love to hear if you've followed along with these articles and if they've helped in any way. We would also love constructive criticism as we're trying to help other van owners really get good information on a basic Subaru swap. Please email busaru@busaru.com to leave some feedback, we'd love it!